Personalization of powered surgical devices

ABSTRACT

A surgical instrument includes a motor configured to actuate end effector; a communication interface configured to couple to a configuration device; and a controller coupled to the motor and the communication interface, the controller includes a memory configured to store an operational parameter for operating the motor, the controller configured to modify the operational parameter based on configuration data received from the configuration device.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of and priority to U.S. Provisional Patent Application No. 62/271,044 filed Dec. 22, 2015, the entire disclosure of which is incorporated by reference herein.

BACKGROUND

1. Technical Field

The present disclosure relates to electromechanical surgical system and their methods of use. More specifically, the present disclosure relates to reprogrammable and/or reconfigurable electromechanical surgical instruments.

2. Background of Related Art

Linear clamping, cutting, and stapling surgical devices may be employed in surgical procedures to resect tissue. Conventional linear clamping, cutting, and stapling devices include a handle assembly, an adapter assembly extending from the handle assembly, and a surgical loading unit detachably coupled to the adapter assembly. The surgical loading unit includes a pair of opposing gripping jaw members, which clamp about the tissue. In this device, one or both of the two gripping members, such as the anvil portion, moves or pivots relative to the overall structure. The actuation of the surgical device may be controlled by a grip trigger maintained in the handle assembly.

In addition to the gripping members, the surgical loading unit may also include a stapling mechanism. One of the gripping members of the surgical loading unit includes a staple cartridge receiving region and a mechanism for driving the staples up through the clamped end of the tissue against the anvil portion, thereby sealing the tissue. The gripping members may be integrally formed with the adapter assembly or may be detachable such that various gripping and stapling elements may be interchangeable.

With conventional mechanical stapling devices, the clinicians had the ability to actuate the devices at a desired speed. However, with introduction of powered surgical stapling devices, which operate by actuation of switches and/or buttons, clinicians no longer have the ability to tailor the firing speed of these instruments. Thus, a need exists for powered surgical stapling devices that may be reconfigured and/or reprogrammed based on specific preferences of the clinician.

SUMMARY

The present disclosure relates to powered surgical instruments, which may be reprogrammed and/or reconfigured by a clinician prior to and/or during use.

According to one embodiment of the present disclosure, a surgical instrument is provided. The surgical instrument includes a motor configured to actuate an end effector; a communication interface configured to couple to a configuration device; and a controller coupled to the motor and the communication interface, the controller includes a memory configured to store an operational parameter for operating the motor, the controller configured to modify the operational parameter based on configuration data received from the configuration device.

According to one aspect of the above embodiment, the surgical instrument further includes a user interface coupled to the controller.

According to another aspect of the above embodiment, the memory stores an interface parameter for configuring the user interface and the controller is further configured to modify the user interface parameter based on the configuration data received from the configuration device.

According to another embodiment of the present disclosure, a surgical instrument is disclosed. The surgical instrument includes: a surgical loading unit; an elongated body including a distal end configured to couple to the surgical loading unit; and a handle assembly including a distal end configured to couple to a proximal end of the elongated body. The handle assembly includes: a motor configured to actuate the surgical loading unit; a communication interface configured to couple to a configuration device; and a controller coupled to the motor and the communication interface. The controller includes a memory configured to store an operational parameter for operating the motor, the controller configured to modify the operational parameter based on configuration data received from the configuration device.

According to an aspect of the above embodiment, the handle assembly further includes a user interface coupled to the controller. The user interface includes a plurality of buttons.

According to another aspect of the above embodiment, the memory stores an interface parameter for configuring the user interface and the controller is further configured to modify the user interface parameter based on the configuration data received from the configuration device.

According to a further aspect of the above embodiment, the controller is further configured to remap button assignment of the plurality of buttons based on the configuration data received from the configuration device.

A method for configuring a surgical device is also contemplated by the present disclosure. The method includes: coupling a communication interface of a surgical device to a configuration device; receiving configuration data from the configuration device; and modifying an operational parameter for operating the surgical device stored in a memory of the surgical device based on the configuration data.

According to one aspect of the above embodiment, the method further includes modifying user interface parameter of a user interface based on the configuration data.

According to another aspect of the above embodiment, modifying the user interface parameter includes remapping button assignments of a plurality of buttons of the user interface.

According to a further aspect of any of the above embodiments, the configuration device is one of a computing device, a flash drive, a memory card, or an RFID.

According to an aspect of any of the above embodiments, the operational parameter is one of a clamping speed, an unclamping speed, a firing rate, a retraction rate, a rotation speed, or an articulation speed.

According to yet another aspect of any of the above embodiments, the communication interface is one of a wireless transceiver or a wired port.

Further details and aspects of exemplary embodiments of the present disclosure are described in more detail below with reference to the appended figures.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present disclosure are described herein with reference to the accompanying drawings, wherein:

FIG. 1A is a perspective view of components of a hand-held, electromechanical surgical instrument according to an embodiment of the present disclosure;

FIG. 1B is a perspective view of an embodiment of an adapter assembly of the surgical instrument of FIG. 1A according to an embodiment of the present disclosure;

FIG. 1C is a side view of a surgical loading unit including an end effector of the surgical instrument of FIG. 1A according to an embodiment of the present disclosure; and

FIG. 2 is a schematic of the surgical instrument of FIG. 1A according to an embodiment of the present disclosure.

DETAILED DESCRIPTION

As used herein, the terms parallel and perpendicular are understood to include relative configurations that are substantially parallel and substantially perpendicular up to about + or −10 degrees from true parallel and true perpendicular.

Embodiments of the presently disclosed surgical instruments including handle assemblies, adapter assemblies, and surgical loading units thereof, are described in detail with reference to the drawings, in which like reference numerals designate identical or corresponding elements in each of the several views. As used herein, the term “distal” refers to that portion of the surgical instrument, adapter assembly, handle assembly, loading unit, or component thereof, farther from the user, while the term “proximal” refers to that portion of the surgical instrument, adapter assembly, handle assembly, loading unit or component thereof, closer to the user.

The present disclosure provides a surgical instrument that includes a handle assembly, a surgical loading unit, and an adapter assembly that interconnects the surgical loading unit with the handle assembly. The surgical instrument includes a motor that is controlled by a controller, which may be reprogrammed and/or reconfigured by a clinician to tailor operating characteristics of the surgical instrument.

With reference to FIGS. 1A-C, a surgical instrument 10, in accordance with an embodiment of the present disclosure, is shown as a powered, hand-held, electromechanical surgical instrument. Surgical instrument 10 includes a handle assembly 100 configured for selective attachment thereto with any one of a number of adapter assemblies 200, and, in turn, each unique adapter assembly 200 is configured for selective connection with any number of surgical loading units 300. Loading unit 300 and adapter assembly 200 are configured for actuation and manipulation by handle assembly 100.

Reference may be made to International Publication No. WO 2009/039506 and U.S. Patent Application Publication No. 2011/0121049, the entire contents of all of which are incorporated herein by reference, for a detailed description of the construction and operation of an exemplary electromechanical, hand-held, powered surgical instrument.

Loading unit 300 of surgical instrument 10 has a proximal portion 302 a configured for engagement with a distal end 206 b of an elongated body 204 of adapter assembly 200. Loading unit 300 includes a distal portion 302 b having end effector 304 extending therefrom. End effector 304 is pivotally attached to distal portion 302 b. End effector 304 includes an anvil assembly 306 and a cartridge assembly 308. Cartridge assembly 308 is pivotable in relation to anvil assembly 306 and is movable between an open or unclamped position and a closed or clamped position for insertion through a cannula of a trocar.

Reference may be made to U.S. Pat. No. 7,819,896, filed on Aug. 31, 2009, entitled “TOOL ASSEMBLY FOR A SURGICAL STAPLING DEVICE”, the entire content of which is incorporated herein by reference, for a detailed discussion of the construction and operation of an exemplary end effector.

Handle assembly 100 further includes a control assembly 108. Control assembly 108 may include one or more finger-actuated control buttons, rocker devices, joystick or other controls, whose input is transferred to the drive mechanism to actuate adapter assembly 200 and loading unit 300. In particular, the drive mechanism of handle assembly 100 is configured to actuate drive shafts, gear components, and/or other mechanical linkages in order to selectively move an end effector 304 of loading unit 300 to rotate end effector 304 about a longitudinal axis “X” defined by surgical instrument 10 relative to handle assembly 100, to move a cartridge assembly 308 relative to an anvil assembly 306 of end effector 304, and/or to fire a stapling and cutting cartridge within cartridge assembly 308 of end effector 304.

With reference to FIG. 1A, handle assembly 100 defines a nose or connecting portion 110 configured to accept a corresponding drive coupling assembly 210 of adapter assembly 200. Connecting portion 110 of handle assembly 100 has a cylindrical recess (not shown) that receives drive coupling assembly 210 of adapter assembly 200 when adapter assembly 200 is mated to handle assembly 100. Connecting portion 110 houses one or more rotatable drive connectors (not shown) that interface with corresponding rotatable connector sleeves of adapter assembly 200.

When adapter assembly 200 is mated to handle assembly 100, each of the rotatable drive connectors (not shown) of handle assembly 100 couples with a corresponding rotatable connector sleeve of adapter assembly 200. In this regard, the interface between a plurality of connectors of handle assembly 100 and a plurality of corresponding connector sleeves of adapter assembly 200 are keyed such that rotation of each of the drive connectors of handle assembly 100 causes rotation of the corresponding connector sleeves of adapter assembly 200.

The mating of the drive connectors of handle assembly 100 with the connector sleeves of adapter assembly 200 allows rotational forces to be independently transmitted via each of the three respective connector interfaces. The drive connectors of handle assembly 100 are configured to be independently rotated by the drive mechanism of handle assembly 100.

Since each of the drive connectors of handle assembly 100 has a keyed and/or substantially non-rotatable interface with the respective connector sleeves of adapter assembly 200, when adapter assembly 200 is coupled to handle assembly 100, rotational force(s) are selectively transferred from the drive mechanism of handle assembly 100 to adapter assembly 200.

The selective rotation of drive connector(s) of handle assembly 100 allows surgical instrument 10 to selectively actuate different functions of end effector 304. Selective and independent rotation of a first drive connector of handle assembly 100 corresponds to the selective and independent opening and closing of end effector 304, and driving of a stapling/cutting component of end effector 304. Selective and independent rotation of a second drive connector of handle assembly 100 corresponds to the selective and independent articulation of end effector 304 about an articulation axis that is transverse to longitudinal axis “X.” In particular, end effector 304 defines a second or respective longitudinal axis and is movable from a first position in which the second or respective longitudinal axis is substantially aligned with longitudinal axis “X” to at least a second position in which the second longitudinal axis is disposed at a non-zero angle with respect to longitudinal axis “X.” Additionally, the selective and independent rotation of a third drive connector of handle assembly 100 corresponds to the selective and independent rotation of loading unit 300 about longitudinal axis “X” relative to handle assembly 100 of surgical instrument 10.

With continued reference to FIGS. 1A-1C, adapter assembly 200 includes a knob housing 202 and an elongated body 204 extending from a distal end of knob housing 202. Knob housing 202 and elongated body 204 are configured and dimensioned to house the components of adapter assembly 200. Elongated body 204 may be dimensioned for endoscopic insertion. In embodiments, elongated body 204 may be passable through a typical trocar port, cannula or the like. Knob housing 202 may be dimensioned to not enter the trocar port, cannula of the like. Elongated body 204 has a proximal portion 206 a attached to knob housing 202, which is configured to be attached to handle assembly 100. Elongated body 204 also includes a distal portion 206 b configured to be coupled to proximal portion 302 a of loading unit 300. Elongated body 204 further includes a distal cap 208 extending distally from distal portion 206 b. Elongated body 204 additionally includes a cylindrical outer housing 212 and a cylindrical inner housing 214 (FIG. 2) disposed therein.

With reference to FIG. 1A, the handle assembly 100 includes a user interface 120 is shown. The user interface 120 includes a screen 122 and a plurality of buttons 124. The user interface 120 may display various types of operational parameters of the instrument 10 such as “mode” (e.g., rotation, articulation or actuation), which may be communicated to user interface 120 via a sensor, “status” (e.g., angle of articulation, speed of rotation, or type of actuation) and “feedback,” such as whether staples have been fired based on the information reported by the sensors disposed in the instrument 10.

The screen 122 may be any suitable display device, such as an LCD screen, OLED screen, electroluminescent screen and the like. In one embodiment the screen 122 may be a touch screen, supplanting and/or supplementing the buttons 124. The touch screen may incorporate resistive, surface wave, capacitive, infrared, strain gauge, optical, dispersive signal or acoustic pulse recognition touch screen technologies. The touch screen may be used to allow the user to provide input while viewing operational feedback. This approach may enable facilitation of sealing screen components to help sterilize the instrument 10, as well as preventing particle and/or fluid contamination. In certain embodiments, screen may be pivotably or rotatably mounted to the instrument 10 for flexibility in viewing screen during use or preparation (e.g., via a hinge or ball-and-socket mount).

The buttons 124 may be used as input devices for navigating and selecting options from a graphical user interface displayed on the screen 122, such as responding to prompts while navigating user interface menus and selecting various settings, allowing a user input different tissue types, and various sizes and lengths of staple cartridges. In embodiments, the buttons 124 may be used to control the instrument 10 including starting and/or stopping movement of the instrument 10 as well as selecting the pivot direction, speed and/or torque. It is also envisioned that at least one button 124 can be used for selecting an emergency mode that overrides various settings.

The buttons 124 may be formed from a micro-electronic tactile or non-tactile membrane, a polyester membrane, elastomer, plastic or metal keys of various shapes and sizes. Additionally, switches may be positioned at different heights from one another and/or may include raised indicia or other textural features (e.g., concavity or convexity) to allow a user to depress an appropriate switch without the need to look at user interface 120.

With reference to FIG. 2, handle assembly 100 includes a controller 402, a motor driver circuit 404, a power source 406, and a drive mechanism having one or more motors 408, gear selector boxes (not shown), gearing mechanisms (not shown), and the like. Controller 402 may include a processor and a memory, which may be volatile, non-volatile, magnetic, optical, or electrical media, such as read-only memory (ROM), random access memory (RAM), electrically-erasable programmable ROM (EEPROM), non-volatile RAM (NVRAM), or flash memory. The processor may be any suitable logic unit (e.g., control circuit) adapted to perform the operations, calculations, and/or set of instructions described in the present disclosure including, but not limited to, a hardware processor, a field programmable gate array (FPGA), a digital signal processor (DSP), a central processing unit (CPU), an application specific integrated circuit (ASIC), or discrete logic circuitry, a microprocessor, and combinations thereof.

The motor driver circuit 404 controls the operation of the motor 408 including the flow of electrical energy from the power source 406 to the motor 408. The motor driver circuit 404 includes a plurality of sensors 404 a, 404 b, . . . 404 n configured to measure operational state of the motor 408 and the power source 406. The sensors 404 a-n may include voltage sensors, current sensors, temperature sensors, telemetry sensors, optical sensors, and combinations thereof. The sensors 404 a-404 n may measure voltage, current, and other electrical properties of the electrical energy supplied by the power source 406. The sensors 404 a-404 n may also measure rotational speed as revolutions per minute (RPM), torque, temperature, current draw, and other properties of the motor 408. RPM may be determined by measuring the rotation of the motor 408. Position of various drive shafts may be determined by using various linear sensors disposed in or in proximity to the shafts or extrapolated from the RPM measurements. In embodiments, torque may be calculated based on the regulated current draw of the motor 408 at a constant RPM.

The controller 402 includes a plurality of inputs and outputs for interfacing with the driver circuit 404. In particular, the controller 402 receives measured sensor signals from the driver circuit 404 regarding operational status of the motor 408 and the power source 406 and, in turn, outputs control signals to the driver circuit 404 to control the operation of the motor 406 based on the sensor readings and specific algorithm instructions and user configuration.

The handle assembly 100 also includes a communication interface 410 coupled to the controller 402. The communication interface 410 may include a communication port, such as, a universal serial bus (“USB”) port, and/or a wireless interface including, but not limited to Bluetooth®, Wifi®, near field communication, inductive communication, or any other suitable wireless communication protocol.

The handle assembly 100 according to the present disclosure provides for adjustment, modification, and/or reconfiguration of one or more of operational parameters and/or algorithm instructions. In embodiments, reconfiguration data may be stored on a configuration device 500. Configuration device 500 may be any suitable device capable of storing data and communicating the data to the controller 406. Suitable configuration devices 500 include, but are not limited to, a computer, a mobile computing device, a flash drive, a memory card, an RFID, and the like. Configuration data may include parameters for modifying motor control algorithm, which is stored in memory of the controller 406.

The configuration device 500 may also include in addition to or in place of the parameters, software instructions executable by the controller 406. In further embodiments, the configuration data may be stored within the memory of the controller 406, which selects the desired configuration data based on an identifier received from the configuration device 500. The configuration data parameters may also be selected through the user interface 120.

During use, the configuration device 500 is connected to the controller 406 of the handle assembly 100 through the communication interface 410. Connection between the configuration device 500 and the handle assembly 100 depends on the communication interface therebetween. Thus, if RFID is being used to transmit configuration data, the handle assembly 100 may utilize an RFID interrogator. Once the configuration data is processed by the controller 406, the controller 406 modifies the settings of the handle assembly 100. In embodiments, the clinician may select one from a plurality of configurations based on the available configuration data, e.g., if the configuration data includes multiple configurations. Configuration data may include various parameters, such as clamping and unclamping speed, firing rate, retraction rate, rotation and articulation speeds. In embodiments, parameters may include button mapping for the buttons 124 and the buttons of the control assembly 108. This allows for the input configuration to be modified to suit the clinician. The parameters may also be set per surgical case. Each personalization control may have multiple settings, depending on the surgical case being performed and on the personal preference of the clinician.

It will be understood that various modifications may be made to the embodiments of the presently disclosed adapter assemblies. Therefore, the above description should not be construed as limiting, but merely as exemplifications of embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the present disclosure. 

The invention claimed is:
 1. A surgical instrument comprising: a motor configured to actuate at least one end effector; a communication interface configured to couple to a configuration device; a user interface including a plurality of buttons; and a controller coupled to the motor and the communication interface, the controller including a memory configured to store at least one operational parameter for operating the motor, the controller configured to modify the at least one operational parameter based on configuration data received from the configuration device and remap button assignment of the plurality of buttons based on the configuration data received from the configuration device.
 2. The surgical instrument according to claim 1, wherein the memory stores at least one interface parameter for configuring the user interface and the controller is further configured to modify the at least one user interface parameter based on the configuration data received from the configuration device.
 3. The surgical instrument according to claim 1, wherein the configuration device is selected from the group consisting of a computing device, a flash drive, a memory card, and an RFID.
 4. The surgical instrument according to claim 1, wherein the at least one operational parameter is selected from the group consisting of a clamping speed, an unclamping speed, a firing rate, a retraction rate, a rotation speed, and an articulation speed.
 5. The surgical instrument according to claim 1, wherein the communication interface is at least one of a wireless transceiver or a wired port.
 6. A surgical instrument comprising: a surgical loading unit; an elongated body including a distal end configured to couple to the surgical loading unit; and a handle assembly including a distal end configured to couple to a proximal end of the elongated body, the handle assembly including: a motor configured to actuate the surgical loading unit; a communication interface configured to couple to a configuration device; a user interface including a plurality of buttons; and a controller coupled to the motor and the communication interface, the controller including a memory configured to store at least one operational parameter for operating the motor, the controller configured to modify the at least one operational parameter based on configuration data received from the configuration device and remap button assignment of the plurality of buttons based on the configuration data received from the configuration device.
 7. The surgical instrument according to claim 6, wherein the memory stores at least one interface parameter for configuring the user interface and controller is further configured to modify the at least one user interface parameter based on the configuration data received from the configuration device.
 8. The surgical instrument according to claim 6, wherein the configuration device is selected from the group consisting of a computing device, a flash drive, a memory card, and an RFID.
 9. The surgical instrument according to claim 6, wherein the at least one operational parameter is selected from the group consisting of a clamping speed, an unclamping speed, a firing rate, a retraction rate, a rotation speed, and an articulation speed.
 10. The surgical instrument according to claim 6, wherein the communication interface is at least one of a wireless transceiver or a wired port.
 11. A method for configuring a surgical device comprising: coupling a communication interface of a surgical device to a configuration device; receiving configuration data from the configuration device; modifying at least one operational parameter for operating the surgical device stored in a memory of the surgical device based on the configuration data; and remapping button assignments of a plurality of buttons of a user interface.
 12. The method according to claim 11, further comprising: modifying at least one user interface parameter of a user interface based on the configuration data.
 13. The method according to claim 12, wherein the at least one operational parameter is selected from the group consisting of a clamping speed, an unclamping speed, a firing rate, a retraction rate, a rotation speed, and an articulation speed. 